This is a great project that shows with some lifecycle analysis, process optimization, and renewable energy investment, the environmental impacts of manufacturing can be reduced significantly.

The Joint Reconstruction Attune Total Knee system from DePuy Synthes Companies of Johnson & Johnson is a surgical replacement knee that came out of one of the company’s largest research and development projects. It contains proprietary fixed bearing technology called the Attune Logiclock Tibial Base designed to optimize size and fit for patients. Johnson & Johnson redesigned the process for the Logiclock’s entire life cycle, adding efficiencies and reducing material usage.

The Attune Total Knee System aims to address the clinical needs of patients, surgeons, and hospital providers. Other fixed bearing knee replacement products contain polyethylene inserts held with a perioral locking mechanism, meaning the insert and implant must always be the same size, according to the company. The Logiclock Tibial Base has a centralized locking mechanism, allowing surgeons to use a tibial base that can be upsized or downsized two sizes compared to the insert. Surgeons match the femoral size to the insert size each time, picking the best fit for patients and optimizing stability.

Looking at the Logiclock’s life cycle, Johnson & Johnson saw room for improvements in the foundry casting process required for the tibial base components, which uses large amounts of alloy. Johnson & Johnson redesigned the process. That resulted in an average reduction of 5 kilograms overall metal consumption per single runner system, equivalent to a 33% reduction per component, the company reported. In addition, the production facility that produces the Logiclock installed a 3 megawatt wind turbine that generates approximately 40% of the site’s electrical energy annually, resulting in a 31% carbon dioxide reduction per part produced.

A new process was created to make the cleaning and passivation line more efficient, resulting in a 24% reduction in water usage as well as a reduction in the total amount of cleaning chemicals used. The company says these reductions in the Attune Knee System Logiclock Tibial Base production were significant improvements in the past year.